JCB 150 ROBOT Service Repair Manual SN678000 Onwards PDF

General Information 1
Care & Safety 2

R Routine Maintenance 3
Attachments A
Body & Framework B
Service
Manual Electrics C
Controls D
ROBOT
150, 165 Hydraulics E
Transmission F
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Brakes G
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/8500 Engine K

Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by
JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for all the
machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
A = Attachments
B = Body & Framework ...etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later
issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each
alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing
forwards.
9803/8500 Issue 1
Section 1 General Information Section 1
i i
Contents Page No.

Identifying your Machine 1-1
Torque Settings 2-1
Service Tools
- Numerical List 3-1
- Electrics 4-1
- Hydraulics 4-2
Sealing and Retaining Compounds 5-1
9803/8500 Issue 1
1-1 Identifying your Machine 1-1
The serial number of the chassis, engine, lift arm and

hydraulic pump unit positively identify the type of JCB Skid
Steer Loader you have.
Machine Identification Plate

The machine identification plate A is located as shown. It is
stamped with the serial numbers of the major individual units.
A
S173720
Typical Vehicle Identification Number (VIN)
SLP 165 S B V E 677001
1 2 3 4 5 6 7
J.C.BAMFORD EXCAVATORS LTD.
ROCESTER, STAFFS, ENGLAND.
1 World Manufacturer Identification
R
CONSTRUCTOR MADE IN UK
2 Machine Model
Vehicle Identification No. Product Identification No.
3 Machine Type (S = Standard, H = High-flow)
ENGINE SERIAL No. WEIGHT
4 Build Type (A = Canopy, B = Cab)
PUMP SERIAL No. YEAR OF MANUFACTURE
5 Year of Manufacture: MODEL 80/1269/EEC MODEL 80/1269/EEC
T = 1996 1 = 2001 POWER KW R.P.M. POWER KW R.P.M.
150 35 2800 1CX 35 2800
V = 1997 2 = 2002 165 35 2800 1CX HF 35 2800
W = 1998 3 = 2003 165 HF 35 2800 185 52 2200
185 HF 52 2200
X = 1999 4 = 2004
Y = 2000 5 = 2005 817/04437
6 Manufacturer Location (E = England)

7 Product Identification Number (PIN)
9803/8500 Issue 5
1-2 Identifying your Machine 1-2
Unit Identification
* The engine serial number on XUD engines is stamped on a
machined area B on the top of the cylinder block. On JCB
Diesel engines the number is stamped on a label G on the
left side of the cylinder block.
The chassis serial number is stamped on the front edge of

the right hand mudguard as shown at C. On early machines
the serial number is stamped on the right hand side of the
machine as shown at F. B
S173730
The lift arm serial number is stamped on the rear of the lift
arm as shown at D.
The hydraulic pump unit serial number is stamped on a plate

G
on the top of the pump at E.
If any of the above units are replaced with new ones, the
relevant serial number on the Machine Identification Plate will
be superseded. Either stamp the plate with the new number
or stamp out the old number.
S255430
C
F
S173742
E
S173760 S173750
Y
Left Side, Right Side
In this manual, 'left' X and 'right' Y mean your left and right
when you are seated correctly in the machine.
X S173660
9803/8500 Issue 2*
2-1 Torque Settings 2-1
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
UNF Grade 'S' Bolts
Bolt Size Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft
1/4 (6.3) 7/16 14 1.4 10

* 5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500
Metric Grade 8.8 Bolts
Bolt Size Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
9803/8500 Issue 2*
3-1 Service Tools 3-1
Numerical List
Page No. Page No.
1406/0011 Bonded Washer 4-3 892/00268 Flow Monitoring Unit 4-2
1406/0018 Bonded Washer 4-3 892/00269 Sensor Head 4-2
1406/0021 Bonded Washer 4 - 2/4 - 3 892/00270 Load Valve 4-2
1406/0029 Bonded Washer 4-3 892/00271 Adapter 4-2
1604/0003 Adapter 4-3 892/00272 Adapter 4-2
1604/0004 Adapter 4-3 892/00274 Adapter 4-3
1604/0006 Adapter 4 - 2/4 - 3 892/00275 Adapter 4-2
1606/0003 Adapter 4-3 892/00276 Adapter 4-2
1606/0004 Adapter 4-3 892/00277 Adapter 4-2
1606/0007 Adapter 4-3 892/00278 Gauge 4-3
1606/0008 Adapter 4-3 892/00279 Gauge 4-3
1606/0009 Adapter 4-3 892/00281 AVO Meter 4-1
1612/0006 Adapter 4-2 892/00282 Shunt 4-1
* 4101/0251 Threadlocker and Sealer 5-1 892/00283 Tool Kit Case 4-1
* 4101/0451 Threadlocker 5-1 892/00284 Tachometer 4-1
* 4101/0552 Threadlocker and Sealer (High Strength) 5 - 1 892/00285 Hydraulic Oil Temperature Probe 4-1
* 4101/0651 Retainer (High Strength) 5-1 892/00286 Surface Temperature Probe 4-1
* 4102/0551 High Strength Threadlocker 5-1 892/00706 Test Probe 4-3
4102/1201 Multi-Gasket 5-1 892/00858 Pump Support Bracket 4-3
* 4104/0251 Activator (Aerosol) 5-1 892/00923 A.R.V Test Block - Commercial Hyd. 4-3
* 4104/0253 Activator (Bottle) 5-1 992/09300 Spanner 4-3
* 4104/1557 JCB Cleaner/Degreaser 5-1 992/09400 Spanner 4-3
816/00189 Blanking Cap 4-4 992/09500 Spanner 4-3
816/00190 Blanking Cap 4-4 992/09600 Spanner 4-3
816/00193 Blanking Cap 4-4 993/68100 Slide Hammer 4-4
816/00196 Blanking Cap 4-4 993/85700 Battery Tester 4-1
816/00197 Blanking Cap 4-4 993/99510 Half Moon Spanner 4-4
816/00294 Blanking Cap 4-4
816/15118 Pressure Test Adapter 4-2 The following parts are replacement items for kits and would
816/20008 Adapter 4-2 normally be included in the kit numbers quoted above.
816/50043 'T' Adapter 4-4
816/55038 Pressure Test 'T' Adapter 4-2 Replacement items for kit no. 892/00253
816/55040 Pressure Test 'T' Adapter 4-2 892/00201 Replacement Gauge 4-2
816/60096 'T' Adapter 4-4 892/00202 Replacement Gauge 4-2
892/00047 'T' Adapter 4-4 892/00203 Replacement Gauge 4-2
892/00048 'T' Adapter 4-4 892/00254 Replacement Hose 4-2
892/00055 Blanking Plug 4-4
892/00074 Female Connector 4-4
892/00137 Hose 4-3
892/00223 Hand Pump 4-3
892/00252 A.R.V Test Block - Husco 4-3
892/00253 Pressure Test Kit 4-2
892/00255 Pressure Test Adapter 4-2
892/00262 Pressure Test 'T' Adapter 4 - 2/4 - 3
892/00263 Pressure Test 'T' Adapter 4-2
9803/8500 Issue 8*
Section C - Electrics
AVO Test Kit
1 892/00283 Tool Kit Case
2 892/00281 AVO Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Microtach Digital Tachometer
5 892/00282 Shunt - open type
6 892/00285 Hydraulic Oil Temperature Probe
188230
* 993/85700 Battery Tester
239510
9803/8500 Issue 2*
Section E - Hydraulics
Hydraulic Circuit Pressure Test Kit
892/00253 Pressure Test Kit
892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in2)
* 892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/00254 Replacement Hose
188120
200140
188130
Pressure Test Adapters
Pressure Test 'T' Adapters
892/00255 1/4 in BSP x Test Point
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00256 3/8 in BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSPP x Test Point 892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Flow Test Equipment
892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
188150
9803/8500 Issue 2*
220840
A215880 S270650
892/00858 Pump support bracket - for engine removal. * 892/00252 Test Block for A. R. V. - Husco valves
* 892/00923 Test Block for A. R. V.
- Commercial Hydraulic valves
193850
188140
Hand Pump Equipment
892/00223 Hand Pump Bonded Washers

892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1406/0011 1/4 in BSP
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 1406/0018 1/2 in BSP
892/00706 Test Probe 1406/0021 3/4 in BSP
892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2) 1406/0029 1.1/4 in BSP
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)
193860
193930
Male Adapters - BSP x BSP
1606/0003 3/8 in x 1/4 in

1604/0003 3/8 in x 3/8 in Hexagon Spanners for Ram Pistons and End Caps
1606/0004 1/2 in x 1/4 in
1606/0007 1/2 in x 3/8 in 992/09300 55 mm A/F
1604/0004 1/2 in x 1/2 in 992/09400 65 mm A/F
1606/0008 3/4 in x 3/8 in 992/09500 75 mm A/F
1606/0009 3/4 in x 1/2 in 992/09600 85 mm A/F
1604/0006 3/4 in x 3/4 in
9803/8500 Issue 5*
193880
193870
Male Cone Blanking Plug

Female Cone Blanking Plug
816/00294 1/4 in BSP
892/00055 1/4 in BSP 816/00189 3/8 in BSP
892/00056 3/8 in BSP 816/00190 1/2 in BSP
892/00057 1/2 in BSP 816/00197 5/8 in BSP
892/00059 3/4 in BSP 816/00196 3/4 in BSP
892/00060 1 in BSP'T' 816/00193 1 in BSP
193890 193900
'T' Adapters Female Connectors
892/00047 3/8 in BSP (A) x 1/4 in BSP (B) 892/00074 3/8 in BSP x 3/8 in BSP
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)
* 993/68100 Slide Hammer

193910
993/99510 Half Moon Spanner
193920
9803/8500 Issue 2*
5-1 Sealing and Retaining Compounds 5-1
JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket
flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1201
JCB High Strength Threadlocker A high strength locking fluid for use with threaded
components. 4102/0551
JCB Retainer (High Strength) For retaining parts which are unlikely to be dismantled. 4101/0651
JCB Threadlocker & Sealer A medium strength locking fluid for sealing and
retaining nuts, bolts, and screws up to 50 mm dia.,
and for hydraulic fittings up to 25 mm dia. 4101/0251
JCB Threadlocker & Sealer A medium to high strength locking fluid for retention and
(High Strength) sealing of ram piston heads. 4101/0552
JCB Threadlocker A locking fluid for use on threads larger than 50 mm dia. 4101/0451
JCB Activator A cleaning primer which speeds the curing rate of

anaerobic products. 4104/0251 Aerosol
4104/0253 Bottle
JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic

adhesives and sealants. 4104/1557 Aerosol
The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with
effect from January 1997 (see MI 563/H, 507/HA, 511/E). The list above has been changed accordingly.
References to these products on subsequent pages in this service manual will be progressively updated but for convenience a
cross reference table is shown below.
Old Description Old Part Number New Description New Part Number
JCB High Strength Threadlocker 4102/0502 JCB High Strength Threadlocker 4102/0551
JCB High Strength Retainer 4101/0602 JCB Retainer (High Strength) 4101/0651
JCB Lock & Seal 4101/0202 JCB Threadlocker & Sealer 4101/0251
Loctite 243 4101/1101 Use 4101/0251
Loctite 262 4101/0502 JCB Threadlocker & Sealer (High Strength) 4101/0552
Loctite 932 4101/0402 JCB Threadlocker 4101/0451
Loctite Activator N 4104/0101 Aerosol JCB Activator 4104/0251

4104/0102 Bottle 4104/0253
JCB Cleaner & Degreaser 4104/1538 Aerosol JCB Cleaner/Degreaser 4104/1557
9803/8500 Issue 5
Section 2 Care and Safety Section 2
i i
Contents Page No.

Safety Notices 1-1
General Safety 2-1
Operating Safety 3-1
Maintenance Safety 4-1
Safety Decals 5-1
9803/8500 Issue 1
1-1 1-1
Safety Notices
In this publication and on the machine there are safety notices. Each notice starts with a
signal word. The signal word meanings are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable
that the operator (or others) could be killed or seriously injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could
be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices could result
in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3
9803/8500 Issue 1
2-1 2-1
All construction and agricultural equipment can be

hazardous. When a JCB machine is correctly operated and
properly maintained, it is a safe machine to work with. But
when it is carelessly operated or poorly maintained it can
become a danger to you (the operator) and others.
Do not work with the machine until you are sure that you can
control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,

ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6
General Safety
! WARNING
! WARNING Clothing
Decals You can be injured if you do not wear the proper clothing.
You can be injured if you do not obey the decal safety Loose clothing can get caught in the machinery. Wear
instructions. Keep decals clean. Replace unreadable or protective clothing to suit the job. Examples of protective
missing decals with new ones before operating the machine. clothing are: a hard hat, safety shoes, safety glasses, a well
Make sure replacement parts include warning decals where fitting overall, ear-protectors and industrial gloves. Keep cuffs
necessary. fastened. Do not wear a necktie or scarf. Keep long hair
INT-1-3-4 restrained.
INT-1-3-6
! WARNING
Care and Alertness ! WARNING
All the time you are working with or on the machine, take Lifting Equipment
care and stay alert. Always be careful. Always be alert for You can be injured if you use faulty lifting equipment. Make
hazards. sure that lifting equipment is in good condition. Make sure
INT-1-3-5 that lifting tackle complies with all local regulations and is
suitable for the job. Make sure that lifting equipment is strong
enough for the job.
INT-1-3-7
! WARNING
Raised Attachments
Raised attachments can fall and injure you. Do not walk or
work under raised attachments unless they are safely
blocked.
INT-1-3-8
9803/8500 Issue 2
3-1 3-1
Operating Safety
! WARNING ! WARNING
Controls Exhaust Gases
You or others can be killed or seriously injured if you operate Breathing the machine exhaust gases can harm and possibly
the control levers from outside the cab. Operate the control kill you. Do not operate the machine in closed spaces without
levers only when you are correctly seated inside the cab. making sure there is good ventilation. If possible, fit an
INT-2-1-3
exhaust extension. If you begin to feel drowsy, stop the
machine at once. Get out of the cab into fresh air.
! WARNING INT-2-1-10
Machine Limits
Operating the machine beyond its design limits can damage ! WARNING
the machine, it can also be dangerous. Do not operate the Passengers
machine outside its limits. Do not try to upgrade the machine Passengers in or on the machine can cause accidents. The
performance with unapproved modifications. JCB Skid Steer Loader is a one man machine. Do not carry
INT-2-1-4
passengers.
INT-2-2-2
! WARNING
Entering/Leaving ! WARNING
When entering and leaving the cab, use the step and Communications
handrails. Make sure the step, handrails and your boot soles Bad communications can cause accidents. Keep people
are clean and dry. Do not jump from the machine. Do not use around you informed of what you will be doing. If you will be
the machine controls or Safety Restraint Bar as handholds, working with other people, make sure any hand signals that
use only the handrails. may be used are understood by everybody. Work sites can
3-1-1-1
be noisy, do not rely on spoken commands.
INT-2-2-3
! WARNING
Engine ! WARNING
The engine has rotating parts. Do not open the engine cover Ramps and Trailers
while the engine is running. Do not use the machine with the Water, mud, ice, grease and oil on ramp or trailers can cause
cover open. serious accidents. Make sure ramps and trailers are clean
INT-2-1-6
before driving onto them. Use extreme caution when driving
onto ramps and trailers. Always reverse up a ramp if
! WARNING unloaded, travel forwards if loaded.
ROPS/FOPS Structure 3-1-1-3/1
The machine is fitted with a Roll Over Protection Structure
(ROPS) and a Falling Objects Protection Structure (FOPS). ! DANGER
You could be killed or seriously injured if you operate the
Sparks
machine with a damaged or missing ROPS/FOPS. If the
Explosions and fire can be caused by sparks from the
ROPS/FOPS has been in an accident, do not use the
exhaust or the electrical system. Do not use the machine in
machine until the structure has been renewed. Modifications
closed areas where there is flammable material, vapour or
and repairs that are not approved by the manufacturer may
dust.
be dangerous and will invalidate the ROPS/FOPS
INT-2-2-10
certification.
! WARNING
INT-2-1-9/3
! WARNING Attachments
Use only JCB approved attachments. Non-approved
Seat Belts
attachments, modified to fit the Skid Steer Loader, could
The ROPS/FOPS cab is designed to give you protection in
cause damage to the machine, and/or make it unsafe. The
an accident. If you do not wear your seat belt, you could be
use of non-approved attachments could invalidate your
thrown around inside the cab or thrown out of the machine
warranty.
and crushed. You must wear a seat belt when using the
3-1-2-1
machine. Fasten the seat belt before starting the engine.
2-2-1-9
9803/8500 Issue 2
4-1 4-1
Maintenance Safety
! WARNING ! WARNING
Repairs Battery Gases
Do not try to do repairs or any other type of maintenance Batteries give off explosive gases. Keep flames and sparks
work you do not understand. To avoid injury and/or damage away from the battery. Do not smoke close to the battery.
get the work done by a specialist engineer. Make sure there is good ventilation in closed areas where
GEN-1-5
batteries are being used or charged. Do not check the
battery charge by shorting the terminals with metal; use a
! WARNING hydrometer or voltmeter.
Metal Splinters INT-3-1-8
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to ! WARNING
remove and fit metal pins. Always wear safety glasses. Battery Terminals
INT-3-1-3
The machine is negatively earthed. Always connect the
negative pole of the battery to earth.
! WARNING
Electrical Circuits When connecting the battery, connect the earth (-) lead last.
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection When disconnecting the battery, disconnect the earth (-) lead
can cause injury or damage. first.
iNT3-1-4 INT-3-1-9
! WARNING ! WARNING
Communications Hydraulic Fluid
Bad communications can cause accidents. If two or more Fine jets of hydraulic fluid at high pressure can penetrate the
people are working on the machine, make sure each is skin. Do not use your fingers to check for hydraulic fluid
aware of what the others are doing. Before starting the leaks. Do not put your face close to suspected leaks. Hold a
engine make sure the others are clear of the danger areas; piece of cardboard close to suspected leaks and then inspect
examples of danger areas are: the rotating blades and belt the cardboard for signs of hydraulic fluid. If hydraulic fluid
on the engine, the attachments and linkages, and anywhere penetrates your skin, get medical help immediately.
beneath or behind the machine. People can be killed or INT-3-1-10/1
injured if these precautions are not taken.
INT-3-1-5 ! WARNING
Hydraulic Pressure
! WARNING It is not possible to vent all residual pressure. Loosen the
Petrol connection one full turn and allow the pressure to dissipate.
Do not use petrol in this machine. Do not mix petrol with the Keep face and hands well clear of pressurised hydraulic oil
diesel fuel; in storage tanks the petrol will rise to the top and and wear protective glasses.
form flammable vapours. HYD 4-3
INT-3-1-6
! DANGER
! WARNING
Electrolyte
Battery Battery electrolyte is toxic and corrosive. Do not breathe the
A battery with frozen electrolyte can explode if it is used or gases given off by the battery. Keep the electrolyte away
charged. Do not use a machine with a frozen battery. To help from your clothes, skin, mouth and eyes. Wear safety
prevent the battery from freezing, keep the battery fully glasses. See Battery in MAINTENANCE section for First Aid
charged. treatment.
INT-3-1-7
INT-3-2-1/2
! WARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the
machine. Do not smoke while refuelling the machine or
working on the engine. Do not refuel with the engine running.
There could be a fire or injury if you do not follow these
precautions.
INT-3-2-2
9803/8500 Issue 2
4-2 4-2
Maintenance Safety (cont'd)
! WARNING ! CAUTION
Oil Rams
Oil is toxic. If you swallow any oil, do not induce vomiting, The efficiency of the rams will be affected if they are not kept
seek medical advice. Used engine oil contains harmful free of solidified dirt. Clean dirt from around the rams
contaminants which can cause skin cancer. Do not handle regularly. When leaving or parking the machine, close all
used engine oil more than necessary. Always use barrier rams if possible to reduce the risk of weather corrosion.
cream or wear gloves to prevent skin contact. Wash skin INT-3-2-10
contaminated with oil thoroughly in warm soapy water. Do
not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
! CAUTION
Cleaning
! WARNING Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
Soft Ground solvents.
A machine can sink into soft ground. Never work under a INT-3-2-11
machine on soft ground.
INT-3-2-4
! CAUTION
'O' rings, Seals and Gaskets
! WARNING Badly fitted, damaged or rotted 'O' rings, seals and gaskets
Tyres and Rims can cause leakages and possible accidents. Renew
Over-inflated or over-heated tyres can explode. Follow the whenever disturbed unless otherwise instructed. Do not use
instructions in this manual for inflating the tyres. Do not weld Trichloroethane or paint thinners near 'O' rings and seals.
or cut rims. Get a tyre/wheel specialist to do any repair work. INT-3-2-12
INT-3-2-6
! WARNING
! WARNING Hydraulic Hoses
Fires Damaged hoses can cause fatal accidents. Inspect the
If your machine is equipped with a fire extinguisher, make hoses regularly for:
sure it is checked regularly. Keep it in the operator's cab until Damaged end fittings
you need to use it. Do not use water to put out a machine Chafed outer covers
fire, you could spread an oil fire or get a shock from an Ballooned outer covers
electrical fire. Use carbon dioxide, dry chemical or foam Kinked or crushed hoses
extinguishers. Contact your nearest fire department as Embedded armouring in outer covers
quickly as possible. Firefighters should use self-contained Displaced end fittings.
breathing apparatus. INT-3-3-2
INT-3-2-7/1
! WARNING
! WARNING Always wear safety glasses when dismantling assemblies
Hot Coolant containing components under pressure from springs. This will
The cooling system is pressurised when the engine is hot. protect against eye injury from components accidentally
Hot coolant can spray out when you remove the radiator cap. flying out.
Let the system cool before removing the radiator cap. To GEN-6-2
remove the cap; turn it to the first notch and let the steam
pressure escape, then remove the cap.
INT-3-2-9
9803/8500 Issue 2
5-1 5-1
Safety Decals
! WARNING
Decals on the machine warn you of particular hazards. Each
decal is attached close to a part of the machine where there
is a possible hazard. Read and make sure you understand
the safety message before you work with or on that part of
the machine.
Keep all decals clean and readable. Replace lost or

damaged decals. The decals and their attachment points are
shown on the following pages. Each decal has a part number
printed on it, use this number to order a new decal from your
JCB distributor.
INT-3-3-3
! WARNING
If you need eye-glasses for reading, make sure you wear
them when reading the safety decals. Decals are
strategically placed around the machine to remind you of
possible hazards. Do not over-stretch or place yourself in
dangerous positions to read the decals.
INT-3-3-4
9803/8500 Issue 2
5-2 5-2
Safety Decals (cont'd)
9803/8500 Issue 2
Section 3 Routine Maintenance Section 3
i i
Contents Page No.

Fluids, Capacities and Lubricants 1-1
Lubricants
Health and Safety 1-2
Fuel System 2-1
Service Schedules 3-1
Loader Arm Safety Strut 4-1
Greasing 5-1
* Body and Framework

Oiling 6-1
Cleaning Cab Interior 6-4
Checking Seat Belt Condition and Security 6-4
Electrical System
Battery Safety 7-1
Checking the Electrolyte Level 7-2
Changing the Light Bulbs 7-3
Hydraulic System
Checking the Fluid Level 8-1
Changing the Filter 8-1
* Transmission
Drive Chain Lubrication up to machine number 677999 9-1
- Checking the Oil Levels 9-1
- Changing the Oil 9-1
Drive Chain Lubrication from machine number 678000 9-2
- Checking the Oil Levels 9-2
- Changing the Oil 9-2
Adjusting the Drive Chain Tension 9-3
Tyres and Wheels 9-4
- Inflating the Tyres 9-4
- Replacing Segments of Optional
Non-Inflatable Tyres 9-4
- Checking the Wheelnut Torques 9-4
- Tyre Table 9-4
9803/8500 Issue 3*
ii ii
Contents Page No.

Engine
Air Filter up to machine number 677999
- Changing the Elements 10 - 1
Air Filter from machine number 678000
- Changing the Elements 10 - 1A
Checking the Oil Level - Peugeot engine 10 - 2
Changing the Oil and Filter - Peugeot engine 10 - 2
* Checking the Oil Level - JCB Diesel engine 10 - 4
* Changing the Oil and Filter - JCB Diesel engine 10 - 4
Draining the Fuel Filter - Peugeot engine 10 - 6
Changing the Fuel Filter Element - Peugeot engine 10 - 6
* Draining the Fuel Filter - JCB Diesel engine 10 - 7
* Changing the Fuel Filter Element - JCB Diesel engine 10 - 7
Cooling System 10 - 8
- Coolant Mixtures 10 - 8
- Checking the Coolant Level 10 - 8
- Changing the Coolant 10 - 9
- Cleaning the Coolant Radiator 10 - 9
Adjusting the Alternator Belt 10 - 10
Fitting a New Alternator Belt 10 - 10
Windscreen Washer 11 - 1
9803/8500 Issue 2*
1-1 1-1
Fluids, Capacities and Lubricants - except North America
ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION
Engine Oil
Peugeot XUD 5 litres JCB 15W/40 Multigrade API CE 15W 40
* JCB Diesel 8.2 litres JCB 10W/30 Multigrade API CC 10W 30
Hydraulic System 65 litres JCB 15W/40 Multigrade API CE 15W 40

JCB 10W/30 Multigrade API CC 10W 30
Cooling System
Peugeot XUD
Total coolant cap. 11 litres Water/Anti-freeze (see Coolant Mixtures) Inhibited Ethanediol AL - 39
Antifreeze 5.5 litres
* JCB Diesel
Total coolant cap. 11 litres JCB Universal Antifreeze/water ASTM D3306-74
Antifreeze 5.5 litres (see Coolant Mixtures)
Fuel System 60 litres Diesel oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Grease Points - JCB Special HP Grease or Lithium based, No. 2 consistency

JCB Special MPL Grease
Chain Case Fill to level plug Engine Oil API CE 15W 40 or API CC 10W 30
Fluids, Capacities and Lubricants - North America
ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION
Engine Oil
Peugeot XUD 1.32 US gal JCB 30W API CD/CE
* JCB Diesel 2.17 US gal JCB 10W or JCB 15W/40 MIL-L-2104E
Hydraulic System 17.2 US gal JCB 30W API CD/CE

JCB 15W/40 (top up only) MIL-L-2104E
Cooling System
Peugeot XUD
Total coolant cap. 2.9 US gal Water/Anti-freeze (see Coolant Mixtures) Inhibited Ethanediol AL - 39
Antifreeze 1.45 US gal
* JCB Diesel
Total coolant cap. 2.9 US gal Permanent Antifreeze ASTM D3306-74
Antifreeze 1.45 US gal
Fuel System 15.8 US gal Diesel oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Grease Points - JCB Moly EP #2 Grease Lithium based, No. 2
Chain Case Fill to level plug Engine Oil API CE 15W 40 or API CC 10W 30
9803/8500 Issue 6*
1-2 1-2
It is most important that you read and understand this information and the publications referred to. Make sure that all
of your colleagues who are concerned with lubricants read it too.
Lubricants - Health and Safety

Hygiene 3 Note the following when removing engine oil from skin:
JCB lubricants are not a health risk when used properly for a Wash your skin thoroughly with soap and water.
their intended purposes. b Using a nail brush will help.
c Use special hand cleansers to help clean dirty hands.
However, excessive or prolonged skin contact can remove d Never use petrol, diesel fuel or paraffin for washing.
the natural fats from your skin, causing dryness and irritation. e Avoid skin contact with oil soaked clothing.
f Don't keep oily rags in pockets.
Low viscosity oils are more likely to do this, therefore g Wash dirty clothing before re-use.
particular care is necessary in handling used oils which can
h Throw away oil-soaked shoes.
be diluted with fuel contamination.
Whenever you are handling oil products you should maintain

First Aid - Oil
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the Swallowing.
relevant publications issued by your local health authority, If oil is swallowed you should not induce vomiting. Get
and note the following: medical advice.
Storage Skin
In the case of excessive skin contact you should wash with
soap and water.
Always keep lubricants out of the reach of children.
Eyes
Never store lubricants in open or unlabelled containers.
In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
Waste Disposal
Spillage
All waste products should be disposed of in accordance with
all the relevant regulations.
Absorb on sand or a locally approved brand of absorbent
granules. Scrape up and remove to a chemical disposal
The collection and disposal of used engine oil should be in
area.
accordance with any local regulations. Never pour used
engine oil into sewers, drains or on the ground. Fires
Handling Extinguish with carbon dioxide, dry chemical or foam.
Firefighters should use self contained breathing apparatus.
New Oil
There are no special precautions needed for the handling or

! WARNING
use of new oil, beside normal care and hygiene practices. Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Used Oil
Extinguish oil and lubricant fires with carbon dioxide, dry
Used engine crankcase lubricants contain harmful chemical or foam. Fire fighters should use self contained
contaminants. In laboratory tests it was shown that used breathing apparatus.
engine oils can cause skin cancer. 7-3-1-3/1
Here are precautions to protect your health when handling

used engine oil:
1 Avoid prolonged, excessive or repeated skin contact

with used engine oils.
2 Apply a barrier cream to the skin before handling used

engine oil.
9803/8500 Issue 1
2-1 2-1
Fuel System
Types of Fuel Low Temperature Fuels
Use good quality diesel fuel to get the correct power and Special winter fuels may be available for engine operation at
performance from your engine. The recommended fuel temperatures below 0 °C (32 °F). These fuels have a lower
specification for JCB engines is given below. viscosity. They also limit wax formation in the fuel at low
temperatures. (Wax forming in the fuel can stop the fuel
Cetane Number: 45 (minimum) flowing through the filter).
Viscosity: 2.5/4.5 Centistokes at 40 °C (104 °F)
Density: 0.835/0.855 kg/litre Flow improvers may also be available. These can be added
(0.872/0.904 lb/pint) to the fuel to reduce wax formation.
Sulphur: 0.5% of mass (maximum)
Distillation: 85% at 350 °C (662 °F)
Petrol
Cetane Number ! WARNING
Do not use petrol in this engine. Do not mix petrol with
Indicates ignition performance. Fuel with a low cetane the diesel fuel. In storage tanks the petrol could rise to
number can cause cold start problems and affect the top and form flammable vapours.
combustion. INT-3-1-6
Viscosity
Filling the Tank
Is the resistance to flow. If this is outside limits, the engine ! WARNING
performance can be affected.
Diesel fuel is flammable; keep naked flames away from
the machine. Do not smoke while refuelling the machine
Density
or working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not
Lower density will reduce engine power. Higher density will
follow these precautions.
increase both engine power and exhaust smoke.
INT-3-2-2
Sulphur
At the end of every working day, fill the tank with the correct
type of fuel.
High sulphur content can cause engine wear. (High sulphur
fuel is not normally found in North America, Europe or
This will prevent condensation from developing in the fuel
Australia.) If you have to use high sulphur fuel you must also
tank overnight.
use a highly alkaline engine lubricating oil; or change the
normal oil more frequently.
We recommend that, if possible, you lock the fuel cap to
prevent theft and tampering.
Distillation
This indicates the mixture of different hydrocarbons in the

fuel. A high ratio of lightweight hydrocarbons can affect the
combustion characteristics.
9803/8500 Issue 1
3-1 3-1
Service Schedules
EVERY 10 OPERATING HOURS OR DAILY
whichever occurs first, for the first 50 Operating Hours AFTER THE FIRST 50 OPERATING HOURS ONLY
only
Change (Engine Stopped)
Check (engine stopped)
1 Engine oil and filter
1 Tightness of wheel bolts *2 Hydraulic fluid filter
3 Fuel filter - drain if necessary (JCB Diesel engine only)
EVERY 10 OPERATING HOURS OR DAILY Note: The engine is supplied with "Running in" oil. This must
whichever occurs first be changed together with engine oil filter after the first 50
operating hours. Failure to complete this could damage the
Clean engine.
1 Machine generally, including cab interior

EVERY 50 OPERATING HOURS OR WEEKLY
Check (engine stopped) whichever occurs first
1 Generally for damage including ROPS/FOPS structure Do the Daily jobs plus:
2 Engine coolant level and condition
3 Fuel system for leaks and contamination Check (Engine Stopped)
4 Hydraulic fluid level
5 Hydraulic system for leaks 1 Oil cooler connections
6 Engine oil level and condition 2 Radiator hoses and condition
7 Engine generally for leaks 3 Alternator belt tension (Peugeot engine only)
8 Tyre pressures and condition 4 Fuel filter - drain if necessary
*9 Windscreen washer level (if fitted)
10 Alternator belt tension (JCB Diesel engine only) Grease
11 Fuel filter - drain if necessary (Peugeot engine only)
1 Loader arm pivot points
12 Seat belt condition and security
2 Lift and compensating ram pivots
Check (Engine Running)
1 Warning lights extinguished EVERY 100 OPERATING HOURS OR 2 WEEKLY

whichever occurs first
2 Operation of all electrical equipment
3 Exhaust for excessive smoke
Do the Daily and 50 hour jobs plus:
4 Operation of all hydraulic services
Clean
Grease
1 Battery terminals
1 Quickhitch pivot pins 2 Quickhitch square locking peg housings
Check (Engine Stopped)
1 Condition of ram piston rods

2 Hoses and pipework for chafing and damage
3 Air cleaner hose security
4 Wiring for chafing
Change
1 Air filter outer element when operating in dusty

conditions
Oil
1 All linkage points

2 Hand throttle lever
3 Throttle pedal hinge bolt (if fitted)
9803/8500 Issue 6*
3-2 3-2
Service Schedules (cont'd)

EVERY 250 OPERATING HOURS OR MONTHLY
EVERY 1000 OPERATING HOURS OR YEARLY
Do the Daily to 100 hour jobs plus: whichever occurs first
Clean Do the Daily to 500 hour jobs plus:
1 Air cleaner dust valve * Check (Engine Stopped)

2 Radiator matrix
3 Hydraulic tank breather 1 Tighten cylinder head bolts (JCB Diesel engine only)
2 Engine cam belt - condition (Peugeot engine only)
Check (Engine stopped) 3 Drive chain tension
1 Tightness of wheel bolts
Check (Engine Running)
Check (Engine running)
1 Exhaust system security 1 Idling speed
2 Exhaust for excessive smoke 2 Maximum governed speed
3 Cooling system for leaks 3 Pulled down speed
4 Throttle system and control pedal 4 Compression
5 Transmission operation 5 M.R.V. pressure
6 Operation of all hydraulic services 6 A.R.V. pressure
7 Operation of control isolation 7 Drive pump pressure
8 Parking brake operation 8 Transmission stall pressure
9 Operation of electrical system
10 Operation of attachments
EVERY 2000 OPERATING HOURS OR 2 YEARLY
Change (Engine Stopped) whichever occurs first
*1 Engine oil and filter Do the Daily to 1000 hour jobs plus:
2 Fuel filter element (JCB Diesel engine only)
Clean
EVERY 500 OPERATING HOURS OR 6 MONTHLY 1 Engine injectors (and test)

Check (Engine Stopped)
Do the Daily to 250 hour jobs plus:
1 Valve clearances (Peugeot engine only)
Check (Engine Stopped) 2 Wheel hub and hydraulic motor bearing clearance,
replace as necessary
1 Engine and pump mounting bolts for tightness
2 Pivot pins and bushes Change
3 Drive chain case oil levels
4 Hydraulic motor mounting bolts 1 Air filter inner element
* 2 Hydraulic fluid - sample/change (clean suction strainer)
5 Battery charge and condition
6 Valve clearances (JCB Diesel engine only) 3 Engine coolant
4 Engine cam belt (Peugeot engine only)
Change 5 Drive chain case oil
1 Hydraulic fluid filter(s)

2 Fuel filter element (Peugeot engine only)
3 Air filter outer element
9803/8500 Issue 6*
4-1 4-1
Loader Arm Safety Strut

Installing Removing
! WARNING ! WARNING
Raised loader arms can drop suddenly and cause You could be killed or injured if the loader control is
serious injury. Before working under raised loader arms, accidentally operated. Make sure no-one comes near
fit the loader arm safety strut. the machine while you remove the safety strut.
2-1-1-6 2-3-1-3
! WARNING
You could be killed or seriously injured if the loader 1 Make sure that the drive control lever is in the neutral
control is accidentally operated. Make sure that no-one (rest) position.
goes near the machine whilst you fit the safety strut.
16-3-1-5 2 Raise the loader arm to take the weight off the safety
strut A. Stop the engine.
1 Empty the shovel or attachment, if appropriate, and raise
the loader arm enough to fit the safety strut. 3 Remove the strut:
2 Stop the engine. a Release securing strap B.

b Remove the safety strut from the lift ram.
3 Fit the strut: c Return the safety strut to its stowage position on the
*
right hand mudguard C.
a Remove the strut from its stowage position on the
* right hand mudguard C.
b Place the strut around the lift ram.
c Secure the strut A into position using strap B.
4 Start the engine.
5 Slowly lower the loader arm onto the safety strut. Stop
the movement immediately the weight of the arm is
supported by the strut.
Note: Extreme care must be taken when lowering the loader

arm onto the safety strut. 'Feather' the lever to lower the
loader arm slowly.
193490
A
C
174170
9803/8500 Issue 2*
5-1 5-1
Greasing
The machine must be greased regularly to keep it working

efficiently. Regular greasing will also increase the machine's
working life.
Grease should be applied with a grease gun, normally two

strokes of the gun should be sufficient. Stop the greasing
procedure when fresh grease appears at the joint. Use the
recommended grease.
In the following illustrations, the grease points are numbered.

Count off the grease points as you apply grease to each one.
Refit the dust caps after greasing.
Quickhitch Pivot Pins - for interval see Service Schedule
Total of 9 grease points.
! WARNING
Safety Strut
If it is necessary to work with the loader arm raised, you
must fit the loader arm safety strut first. (See Loader Arm
Safety Strut).
2-1-1-6
45
23
8
9
67
1
174210
9803/8500 Issue 1
5-2 5-2
Greasing (cont'd)
Loader Arm Pivot Points - for interval see Service Schedule Lift and Compensating Ram Pivots - for interval see
Service Schedule
Total of 2 grease points
Total of 4 grease points
! WARNING
Raised loader arms can drop suddenly and cause
serious injury. Before working under raised loader arms,
fit the loader arm safety strut.
2-1-1-6
12
174220
9803/8500 Issue 1
6-1 6-1
Body and Framework

Oiling - for interval see Service Schedule
X Y
The following points should be lightly lubricated with engine
oil.
A A
Engine Compartment Rear Door Latch A
Switch off the engine and ensure it cannot be started
while you are doing this job.
Oil the inside and outside of latch mechanism A on the A

engine compartment rear door.
174180 193630
Note: Early machines were fitted with an external catch as
shown at X; later machines have a concealed catch as
shown at Y. From September 1996 the door latch is as
shown at Z.
Z
S256960
*
Throttle Pedal (if fitted) B
up to machine number 677999
Oil both points B of the throttle pedal hinge bolt.

B
174250 S255880
9803/8500 Issue 4*
6-2 6-2
Body and Framework (cont’d)

Oiling (cont’d) - for interval see Service Schedule
* Control Linkages - Manual Controls

up to machine number 677999

Tilt the Safety Restraint forward and remove the seat. Oil the
joints of the control linkages A.
A
A
A
A
A A
A
A A A
A A A A
A A
A
A
S256770
9803/8500 Issue 4*
6-3 6-3
Body and Framework (cont’d)

Oiling (cont’d) - for interval see Service Schedule
Control Linkages - Manual Controls

from machine number 678000

Raise the Safety Restraint and remove the seat. Oil the joints
of the control linkages A and B where fitted.
A
A
A
B A A
A
A
A A
A
A
A
A
A
A
S288290
9803/8500 Issue 2
6-4 6-4
Body and Framework (cont'd)

Cleaning Cab Interior - for interval see Service Schedule
Because the machine body base is of solid steel construction

special provision is made for cleaning out the cab. The cab
floor profile incorporates two gutters, one on each side. At
the rear end of each gutter is a blanking plate A which is
secured by two bolts.
1 Lower the loader arm to its lowest position with a shovel

installed.
2 Operate the Loader Arm/Shovel control lever as if to tip

the shovel for unloading. This action will raise the front of A
the machine off the ground.
3 Stop the engine and remove the starter key. 174161
4 If necessary, remove the floor plate in front of the

operator's seat by unscrewing the four bolts securing it to
the chassis. 7 Take whatever steps are necessary to get rid of any dirt
and debris. Get rid of as much water as possible by
5 Loosen the blanking plates A from the ends of the giving the gutters time to drain and by drying out with
chassis gutters - slacken off one bolt and the plate will cloths.
swing away.
8 Once the cab gutters are dry, re-secure the gutter
Note: The illustration shows the left gutter blanking plate. A blanking plates and refit the floor plate.
similar plate is fitted to the right side gutter.
9 Start the engine and crowd the shovel to lower the
6 Hose out the machine floor taking care not to get water machine to the ground.
into the electrical circuits.
Note: Hose pressure should not be too high.
Checking Seat Belt Condition and Security - for interval

see Service Schedule
! WARNING
Replace the seat belt with a new one if it is damaged, if
the fabric is worn, or if the machine has been in an
accident. Fit a new seat belt every three years regardless
of condition.
2-3-1-8
When checking the seat belt, look for signs of fraying and
stretching. Make sure the stitching is not loose or damaged.
Make sure the buckle assembly is working correctly and not
damaged. Fit a new seat belt every three years.
Make sure the belt mounting bolts are undamaged, correctly

fitted and tightened.
9803/8500 Issue 1
7-1 7-1
Electrical System
Battery Safety
! WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn

you if it touches your skin or eyes. Wear goggles. Handle
the battery carefully to prevent spillage. Keep metallic
items (watches, rings, zips etc) away from the battery
terminals. Such items could short the terminals and burn
you.
Set all switches in the cab to OFF before disconnecting

and connecting the battery. When disconnecting the
battery, take off the earth (-) lead first.
When reconnecting, fit the positive (+) lead first.
Re-charge the battery away from the machine, in a well

ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
5-3-4-3
DO THE FOLLOWING FIRST AID, IF

ELECTROLYTE:
GETS INTO YOUR EYES
Flush with water for 15 minutes, get medical help

immediately.
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable
oil.
GETS ONTO YOUR SKIN
Flush with clean water, remove affected clothing.
9803/8500 Issue 1
7-2 7-2
Electrical System (cont'd)

Checking the Electrolyte Level - for interval see Service
Schedule
The battery is mounted in a compartment above the diesel

fuel tank.
1 Stop the engine.
2 Unlatch and remove the battery cover A.

A
3 Remove battery cell cover(s) B.
4 Make sure the level in each cell is 6 mm (1/4 in) above

the plates.
5 If necessary, top up with distilled water.
6 Refit battery cell cover(s) B.
7 Refit the battery cover and latch.

174411
! WARNING
Do not top up the battery with acid. The electrolyte could
boil out and burn you.
2-3-4-6 B
! WARNING
Battery Terminals
The machine is negatively earthed. Always connect the
negative pole of the battery to the earth.
When connecting the battery, connect the earth (-) lead

last.
When disconnecting the battery, disconnect the earth (-)

lead first.
INT-3-1-9
174420
9803/8500 Issue 2
7-3 7-3
Electrics (cont'd)
Changing the Light Bulbs
Worklight Bulb A A
1 Support the light unit B remove screws A.
2 Lift and turn light unit B to gain access to connectors C B

and D.
3 Disconnect at C and D. C
4 Remove the bulb by releasing clips E.
5 Do not touch the new bulb with bare fingers. Fit the
new bulb. D
6 Reassemble the light unit in the reverse order.
E
132930
Cab Interior Light Bulb
1 Carefully lever light unit F from the roof, using a

screwdriver in the slot at one end.
F
2 Ease the spring contact G to release the bulb.
3 Fit new bulb. Make sure the bulb is seated in the spring
contact holes.
4 Refit light unit F, take care not to trap the wires. G 132970
Rotating Beacon Bulb

J
1 Remove the three screws H and remove cover J.
2 Release spring clip K and ease the bulb from its holder H H
L.
3 Disconnect the bulb at M.
4 Do not touch the bulb with bare fingers. Fit the new
bulb. Make sure that the bulb is seated correctly and the
K
spring clip K is secure. M
5 Reassemble the light unit in the reverse order.
L
133010
9803/8500 Issue 1
7-4 7-4
Electrics (cont'd)
Changing the Light Bulbs (cont'd)
Switches and Warning Lights

A
1 With a fine screwdriver ease the Switch/Warning Lights
A from their sockets in the control panel.
2 The bulb holders B can then be pulled from the back of

the Switch/Warning Lights and the bulbs will come with
B
them. C
3 The bulbs C are a straight pull from the holder.
4 Fit the new bulbs.
5 Re-assemble the Switch/Warning Light in the reverse

order. 174290
9803/8500 Issue 1
8-1 8-1
Hydraulic System
! WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
C
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
INT-3-1-10/1 A
Checking the Fluid Level - for interval see Service Schedule
1 Stop the engine.

174390
2 Early machines - Look at the fluid level in the sight glass
A. The level should be between the two marks on the
sight glass.
B
Later machines - Look at the fluid level in the sight glass
B. The level should be at the mark on the sight glass.
If the fluid in the sight glass appears cloudy, then water

* or air has entered the system. The hydraulic pump could C
be severely damaged if the machine is operated.
3 If more fluid is needed, wait for five minutes, open the

hydraulic tank filler cap C and top up with engine oil.
174391
Changing the Filter - for interval see Service Schedule
1 Stop the engine and wait for 5 minutes.

E
2 Open the engine compartment rear door.
3 Loosen the hydraulic tank filler cap C and allow all

pressure to dissipate. Remove the filler cap.
4 Unscrew the old filter canister D, using a chain wrench if

necessary, and discard. C
5 Lubricate seal E on the new filter canister with clean D
engine oil.
6 Screw on the new filter canister hand tight only.
7 Add engine oil through filler point C.

B
8 Refit cap C, run the engine for a few minutes, then re-
check the fluid level.
Note: On machines fitted with the High Flow option a second

* filter is fitted. Repeat procedure for second filter. The two
filter canisters, although visually similar, are different and
must not be mixed.
174401
9803/8500 Issue 3*
9-1 9-1
Transmission
Drive Chain Lubrication Changing the Oil - for interval see Service Schedule
The final drive to the wheels is by chains. A chain casing on 1 Park the machine on level ground.
each side of the machine houses two chains, one to the front
wheel and one to the rear wheel. The chains run in an oil 2 Stop the engine.
bath.
3 On the left side of the machine, remove inspection plug
Checking the Oil Levels - for interval see Service Schedule A.
1 Park the machine on level ground. 4 Place a suitable receptacle under plug B to collect the
oil.
2 Stop the engine.
5 Remove plug B and completely drain the chain casing.
3 On the left side of the machine, remove inspection plug
A and check that the oil level is up to the bottom of the 6 Clean both plugs and their apertures. Replace the
aperture. sealing washers if necessary.
4 If necessary, top up through the aperture using the 7 Refit plug B.

recommended oil. Wipe up any oil spillage.
8 Using the recommended oil, fill the chain casing via plug
5 Check that the washer on plug A is undamaged. Replace A aperture until the oil is level with the bottom of the
if necessary. aperture. Wipe up any oil spillage.
6 Clean plug A and its aperture before refitting. Do not 9 Refit plug A. Do not overtighten or you could strip the
overtighten or you could strip the threads of the housing. threads of the housing.
7 Repeat steps 3 to 6 on the right side of the machine. 10 Repeat steps 3 to 9 for the right side chain casing.
A
B
174360
Note: This diagram shows the location of the chain casing plugs on the left side of the machine. The right side casing is a mirror
image of the left side casing. The rear wheel is shown removed for clarity.
9803/8500 Issue 1
9-2 9-2
Transmission (cont'd)
Drive Chain Lubrication from machine number 678000 Changing the Oil - for interval see Service Schedule
The final drive to the wheels is by chains. A chain casing on 1 Park the machine on level ground.
each side of the machine houses two chains, one to the front
wheel and one to the rear wheel. The chains run in an oil 2 Stop the engine.
bath.
3 On the left side of the machine, remove one of the
Checking the Oil Levels - for interval see Service Schedule inspection cover bottom bolts A and its spring washer.
1 Park the machine on level ground. 4 Place a suitable receptacle under drain plug B to collect
the oil.
2 Stop the engine.
5 Remove plug B and completely drain the chain casing.
3 On the left side of the machine, remove one of the
inspection cover bottom bolts A and its spring washer. 6 Clean plug B and its aperture. Renew the sealing washer
Check that the oil level is up to the bottom of the hole. if necessary.
4 If necessary, top up through the bolt hole using the 7 Refit plug B.
recommended oil. Wipe up any oil spillage.
* 8 Using the recommended oil, fill the chain casing via bolt
5 Clean bolt A, its spring washer and its hole and apply A hole until the oil is level with the bottom of the hole.
JCB Threadlocker & Sealer to the threads of the bolt. Do Wipe up any oil spillage.
not overtighten or you could strip the threads in the *
housing. 9 Clean bolt A, its spring washer and its hole and apply
JCB Threadlocker & Sealer to the threads of the bolt. Do
6 Repeat steps 3 to 6 on the right side of the machine. not overtighten or you could strip the threads in the
housing.
10 Repeat steps 3 to 9 for the right side chain casing.
A
B
S256271
Note: This diagram shows the chain casing on the left side of the machine. The right side casing is a mirror image of the left
side casing. The rear wheel is shown removed for clarity.
9803/8500 Issue 5*
9-3 9-3
Adjusting the Drive Chain Tension
Note: The drive chains on machines after serial no. 676702 4 Remove the rear wheel.
are pre-tensioned during manufacture and there is no
provision for routine adjustment in service. These machines 5 Adjust the tension as described below.
are fitted with a different style hub as shown at Y. Refer to
Wheel Hub Assembly Removal and Replacement a Loosen the six bolts B securing the hub locking ring
(SECTION F) for initial setting procedure. C.
1 Park the machine on firm level ground. b Using a large adjustable spanner, grip the lug on hub
D, rotate the hub until no further movement is
2 Stop the engine and remove the starter key. possible. Mark this position as at X.
3 Jack-up the left side of the machine, positioning the jack c Back off the tension so that the mark on the hub is
under the centre of the chain case between the wheels. 3.5 to 4.0 mm back from that on the locking ring as
Support the machine on blocks. shown.
Note: Ensure that the jack is capable of lifting at least 3000 d Re-tighten the six bolts of hub locking ring C to a
kg (3 tons). torque of 98 Nm (72 lbf ft, 10 kgf m).
6 Refit the rear wheel, tightening the bolts to the correct

torque (see page 3/9 - 3).
Y 7 Repeat steps 3 to 6 for the front wheel.
8 Repeat steps 3 to 7 on the right side of the machine.
S256270
B
C
D
174370
Note: This diagram shows the left side rear wheel removed for adjusting the rear axle chain tension. Other wheels are dealt with
in a similar manner.
9803/8500 Issue 6
9-4 9-4
Tyres and Wheels Replacing Segments of Optional Non-Inflatable Tyres
Inflating the Tyres Non-inflatable tyres are available as an option for use in
environments where a puncture could have serious
! WARNING consequences. These tyres consist of a number of individual
Over-inflated or overheated tyres can explode. Do not segments bolted to the wheel rim.
cut or weld the rims. Get a tyre/wheel specialist to do
any repair work. Damaged segments can be renewed individually. Loosen
5-3-2-4 and remove the four nuts and washers A (two each side of
the wheel). Lift the segment clear by extracting its fixing
These instructions are for adding air to a tyre which is studs from the holes in the wheel rim.
already inflated. If the tyre has lost all its air pressure, call in
a qualified tyre mechanic. The tyre mechanic should use a Fit a new segment in reverse order to removal, then tighten
tyre inflation cage and the correct equipment to do the job. the retaining nuts to a torque of 28 Nm (21 lbf ft, 3 kgf m).
1 Prepare the Wheel
Before you add air to the tyre, make sure it is correctly

fitted on the machine or installed in a tyre inflation cage.
2 Prepare the Equipment

A
Use only an air supply system which includes a pressure
regulator. Set the regulator no higher than 1.38 bar (20
lbf/in 2 , 1.4 kgf/cm 2 ) above the recommended tyre
pressure. See Table below.
Use an air hose fitted with a self-locking air chuck and Checking the Wheel Bolt Torques
remote shut-off valve.
On new machines, and whenever a wheel has been
3 Add the Air removed, check the wheel bolt torques every two hours until
they stay correct.
Make sure that the air hose is correctly connected to the
tyre valve. Clear other people from the area. Stand Every day, before starting work, check that the wheel bolts
behind the tread of the tyre while adding the air. are tight.
Inflate the tyre to the recommended pressure. Do not The correct torques are shown in the tables below.
over-inflate.
8 bolt fixing 6 bolt fixing
Front & Rear Front & Rear
Nm lbf ft kgf m Nm lbf ft kgf m

220 162 22 405 298 41
! WARNING
If, for whatever reason, a wheel bolt is renewed, all the
bolts for that wheel must be changed as a set, since the
remaining bolts may have been damaged.
3-3-2-1
Tyre Table
Robot 150 Robot 165 Robot 150 & 165
Pneumatic Tyres - size 27 x 8.5 x 15 10 x 16.5 700 x R15 XZM
- pressure bar (lbf/in2) 4.1 (60) 3.1 (45) 3.1 (45)
- manufacturer Goodyear (tubeless) Goodyear (tubeless) Michelin

Dico/Armstrong (tubed) DicoArmstrong (tubed)
Non-inflatable Tyres (on special rim) Segmented or Solid Segmented or Solid Segmented or Solid
9803/8500 Issue 1
10 - 1 10 - 1
Engine
* Air Filter up to machine number 677999
Changing the Elements - for interval see Service Schedule 4 Clean inside canister E, and dust valve F.
! CAUTION 5 Carefully insert the new elements into the canister. Make
The outer element must be renewed immediately if the sure they seat correctly by smearing the seals G and H
warning light on the instrument panel illuminates. with grease and checking for a witness mark on the
2-3-3-1 canister base. Fit and tighten nuts A and C.
! CAUTION 6 Make sure that the wire to the Air Filter Blocked switch
Do not run the engine when the outer element has been is attached to the spade connector.
removed.
16-3-3-1 Note: Do not attempt to wash or clean the elements - they
must be renewed.
1 Stop the engine.
Note: Do not run the engine with the dust valve F removed.
2 Gain access to the engine compartment by opening the
compartment rear door. Note: In dusty conditions, the outer element can be cleaned
by blowing through in the reverse direction with clean dry
Open the hinged top cover. compressed air. If the element is damaged, it must be
replaced. A new inner element must be fitted at least every
3 Unscrew wing nut A. Remove the outer element B. Take third time the outer element is changed. As a reminder, mark
care not to tap or knock the element. If necessary, the inner element with a felt tipped pen each time the outer
unscrew nut C and remove the inner element D. element is changed.
B
E
F A
174260
9803/8500 Issue 3*
10 - 1A 10 - 1A
Engine
3 Depress clips A and lift off cover B. Remove outer
Air Filter from machine number 678000 element C. Take care not to tap or knock the element. If
the inner element is to be changed, lift up pulls D and
Changing the Elements - for interval see Service Schedule remove inner element E.
! CAUTION 4 Clean inside the canister G, cover B and dust valve H.

The outer element must be renewed immediately if the
5 Insert the new elements into the canister, pushing them
warning light on the instrument panel illuminates.
2-3-3-1
firmly in so that seals F and J are fully seated. Fit cover
B with dust valve H at the bottom. Push the cover firmly
! CAUTION into position and make sure it is secured by clips A.
Do not run the engine when the outer element has been
removed. 6 Make sure that the wire is connected to the Air Filter
16-3-3-1 Blocked switch.
1 Stop the engine. Note: Do not attempt to wash or clean the elements - they
must only be renewed.
2 Gain access to the engine compartment by opening the
compartment rear door. Note: Do not run the engine with the dust valve H removed.
Open the hinged top cover Note: A new inner element must be fitted at least every third
time the outer element is changed. As a reminder, mark the
inner element with a felt tipped pen each time the outer
element is changed.
G
B
E
C
F B
A
D H
S257920
9803/8500 Issue 1
10 - 2 10 - 2
Engine (cont'd)
* Checking the Oil Level - Peugeot XUD engine
- for interval see Service Schedule
! WARNING
Hot oil and engine components can burn you. Make sure
the engine is cool before doing this job.
2-3-3-2
1 Park the machine on level ground and lower the

attachments to the ground.
2 Stop the engine and remove the starter key.

A
3 Open the engine compartment rear door and hinged top
cover.
4 Check that the oil level is between the two marks on the
dipstick A. B
5 If necessary, add the recommended oil through the filler
point B.
174280
6 Make sure the filler cap and the dipstick are secure.
7 Close and secure the engine compartment hinged top

cover and rear door.
* Changing the Oil and Filter - Peugeot XUD engine

! WARNING
2-3-3-2
This machine can be fitted with an engine oil drain plug kit.
This allows the oil to be safely changed when hot. No special
tools are needed.
C
1 Do Steps 1 to 2 of Checking the Oil Level.
Note: If a blanking plug is fitted, allow the oil sufficient time to

cool down. 199450
2 Open the engine compartment rear door and top cover .
3 Access to the sump drain plug is through a centre line

blanking plate C. Remove the blanking plate and place a
suitable container beneath the machine to catch the oil.
E
* 4 Either remove drain plug to allow oil to flow into the
container or remove dust cap D and, with the free end of
the clear plastic hose in the oil receptacle, screw on the
drain coupling E and clear plastic hose F. This D F
automatically opens the valve, allowing the oil to flow
into the container.
193480
Note: The drain coupling needs to be only hand tight.
9803/8500 Issue 2*
10 - 3 10 - 3
Engine (cont'd)
* Changing the Oil and Filter - Peugeot engine (cont'd)
5 After emptying the sump, unscrew drain coupling E and

replace the dust cap D.
Note: The valve closes automatically as the coupling is

removed. The dust cap need only be hand tight.
6 Unscrew the filter canister G, using a chain wrench if J

necessary. Remember that it will contain some oil.
7 Clean filter head H. H

8 Add clean engine oil to the new filter canister. Allow time G
for the oil to pass through the filter element.
9 Smear the seal J on the new filter canister with clean

engine oil.
10 Screw in the new filter canister - hand tight only.
11 Fill the engine with the recommended oil, to the MAX

mark on the dipstick A, through the filler point B. Wipe off
any spilt oil, refit the filler cap and make sure it is secure. 174310
12 Make sure the engine will not start by removing the

engine shut-off solenoid (ESOS) fuse. Turn the engine
using the starter key until the oil pressure warning light is
extinguished.
13 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has cooled,
check the oil level and, if necessary, top up with clean
engine oil.
14 Close and secure the engine compartment rear door and

hinged top cover.
9803/8500 Issue 3*
10 - 4 10 - 4
Engine (cont'd)
* Checking the Oil Level - JCB Diesel engine
B
! WARNING
2-3-3-2
1 Park the machine on level ground and lower the

attachments to the ground.
2 Stop the engine and remove the starter key. A

3 Open the engine compartment rear door and hinged top
cover.
4 Check that the oil level is within the marked area on the
dipstick A.
5 If necessary, add the recommended oil through the filler

point B.
6 Make sure the filler cap and the dipstick are secure.
7 Close and secure the engine compartment hinged top

cover and rear door.
* Changing the Oil and Filter - JCB Diesel engine

S255840
! WARNING
2-3-3-2
1 Do Steps 1 to 2 of Checking the Oil Level.
2 Open the engine compartment rear door and top cover .
3 Access to the sump drain plug is through the chassis

blanking plate C. Remove the blanking plate and place a
suitable container beneath the machine to catch the oil. C
4 Remove the drain plug D and allow the oil to flow into the D
container.
S256260
5 After emptying the sump, replace the drain plug D and
refit the blanking plate C.
9803/8500 Issue 3*
10 - 5 10 - 5
Engine (cont'd)
* Changing the Oil and Filter - JCB Diesel engine (cont'd)
6 Unscrew the filter canister E, using a chain wrench if

necessary. Remember that it will contain some oil.
7 Clean filter head F.
8 Add clean engine oil to the new filter canister. Allow time
for the oil to pass through the filter element. G
9 Smear the seal G on the new filter canister with clean
engine oil.
10 Screw in the new filter canister - hand tight only.

F
11 Fill the engine with the recommended oil, to the MAX E
mark on the dipstick A, through the filler point B. Wipe off
any spilt oil, refit the filler cap and make sure it is secure.
12 Make sure the engine will not start by removing the

engine shut-off solenoid (ESOS) fuse. Turn the engine
using the starter key until the oil pressure warning light is
extinguished.
S255850
13 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has cooled,
check the oil level and, if necessary, top up with clean
engine oil.
14 Close and secure the engine compartment rear door and

hinged top cover.
9803/8500 Issue 4*
10 - 6 10 - 6
Engine (cont'd)
X
* Draining the Fuel Filter - Peugeot engine machines C
E D
The fuel filter is located on the rear left hand side of the
chassis. Illustrations X show early machines, illustration Y
shows later machines. K
1 Stop the engine.
2 Open the engine compartment rear door. H

3 Drain off any water in the bowl B by opening tap A. J Y
4 Re-tighten tap A.
5 If there is sediment in the bowl B change the element F. F

Changing the Fuel Filter Element - Peugeot engine machines J
1 Stop the engine.

B
J
3 Place a receptacle under the filter to catch any fuel.
Slacken tap A. G
4 Support the bowl B and unscrew bolt C. Remove the bolt L
C, remove and discard washer D and 'O' ring E.
A 174380
5 Remove filter element F, bowl B and base G as a unit.
6 Discard 'O' ring H.
7 Separate element F, bowl B and base G.
8 Remove and discard seals J (3 off), discard 'O' ring L.
9 Lubricate all seals and 'O' rings with correct fuel oil.
10 Fit new seals J (3 off) to base G, bowl B and element F,

fit 'O' ring H to the centre of the element F.
193640
11 Fit element F, bowl B, base G, to the head K.
12 Insert centre bolt C after fitting new washer D and 'O'

ring E. Tighten the bolt C carefully by hand to ensure
X
that all seals are correctly seated. Fit new 'O' ring L to
tap A and insert tap into base G.
13 Torque tighten bolt C to 8-11 Nm (6-8 lbf ft, 0.8-1.1 kgf m).
14 Slacken a fuel line connection at the fuel pump on the

engine or on the engine side of the priming pump M.
15 Prime the fuel pump M until fuel spurts from the M

loosened connection with no entrapped air.
16 Tighten the fuel line connection and check filter for leaks. 174520
Tighten connections or change seals as required.
9803/8500 Issue 2*
10 - 7 10 - 7
Engine (cont'd)
* Draining the Fuel Filter - JCB Diesel engine machines
The fuel filter is located on the rear left side of the chassis. C
1 Stop the engine.
E D
3 Drain off any water in the bowl B by opening tap A. K M

4 Re-tighten tap A.
5 If there is sediment in the bowl B change the element F.

*
Changing the Fuel Filter Element - JCB Diesel engine
H
machines - for interval see Service Schedule
J
1 Stop the engine.

F
3 Place a receptacle under the filter to catch any fuel.
Slacken tap A.
J
4 Support the bowl B and unscrew bolt C. Remove the bolt
C, remove and discard washer D and 'O' ring E.
5 Remove filter element F, bowl B and base G as a unit.

B
6 Discard 'O' ring H.
J
7 Separate element F, bowl B and base G.
G
8 Remove and discard seals J (3 off), discard 'O' ring L.
9 Lubricate all seals and 'O' rings with correct fuel oil. L
10 Fit new seals J (3 off) to base G, bowl B and element F, A
fit 'O' ring H to the centre of the element F. S255820
11 Fit element F, bowl B, base G, to the head K.
12 Insert centre bolt C after fitting new washer D and 'O'

ring E. Tighten the bolt C carefully by hand to ensure
that all seals are correctly seated. Fit new 'O' ring L to
tap A and insert tap into base G.
13 Torque tighten bolt C to 8-11 Nm (6-8 lbf ft, 0.8-1.1 kgf m).
N
14 Slacken bleed screw M and operate the lift pump priming
lever N until fuel spurts from the loosened connection
with no entrapped air.
15 Tighten the bleed screw and check the filter for leaks.
Tighten connections or change seals as required.
Note: If no fuel is moved when the fuel lift pump priming

S255860
lever N is operated, then the pump diaphragm may have
rested in the ‘maximum lift’ position. To move the diaphragm,
9803/8500 Issue 3*
10 - 8 10 - 8
Engine (cont'd)
Cooling System Checking the Coolant Level
* Coolant Mixtures 1 Park the machine on level ground. Stop the engine and
let it cool down.
To prevent the coolant freezing in cold conditions, antifreeze
must be added. On Peugeot engine machines use Inhibited 2 Carefully loosen the cooling system filler cap A just
Ethanediol AL-39 antifreeze (JCB Part Number 4006/0200). enough to let any pressure escape. Remove the cap
when all pressure is released.
Solution Starts to freeze at
50% - 37 °C (- 35 °F) 3 If necessary top up the system to the level indicated
inside the expansion/filler bottle.
On Perkins engine machines use JCB Universal Antifreeze.
4 Refit the filler cap and make sure it is tight.
Solution Maintains circulation Protects against
down to damage down to 5 Run the engine for a while to raise the coolant to working
deg C deg F deg C deg F temperature and pressure. Stop the engine and check
50% -33 -27 -45 -49 for leaks.
Never use less than 45% antifreeze solution otherwise there Illustration X shows machines up to serial no. 677000.
will not be enough corrosion protection.
Illustration Y shows machines from serial no. 677001.
Never use more than 50% antifreeze solution otherwise the
cooling system may be damaged. X
Leave the antifreeze in all the year round as it gives
protection against corrosion.
Check the strength of antifreeze solution at least once a

year, preferably at the start of the cold period. Always renew
the antifreeze every two years.
A
A 50% antifreeze solution should be used even if frost
protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.
! WARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling neat or diluted antifreeze.
7-3-4-4
! WARNING
174321
The cooling system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure the engine is
cool before checking the coolant level or draining the
system. Y
2-3-3-3
S256900
9803/8500 Issue 2*
10 - 9 10 - 9
Engine (cont'd)
Cooling System (cont'd)
Changing the Coolant - for interval see Service Schedule
1 Park the machine on level ground. Stop the engine and

let it cool down. Open the engine compartment rear
door.
B
2 Carefully loosen filler cap A just enough to let any
pressure escape. Remove the cap when all pressure is
released.
*
3 Remove the bottom hose B from the lower box of the
radiator. On JCB Diesel engines, unscrew the cylinder
block drain tap C.
4 Flush the system by pouring clean water into filler cap A.

*
5 Clean and refit bottom hose B. On JCB Diesel engines,
tighten the cylinder block drain tap C.
174331
6 Fill the system to the level indicated inside the
expansion/filler bottle using the necessary anti-freeze
solution.
7 Refit the filler cap A.
8 Check for leaks. C

9 Run the engine for a while to raise the coolant to working
temperature and pressure. Stop the engine and check
for leaks. Check the coolant level and top up if
necessary.
S255870
Cleaning the Coolant Radiator - for interval see Service
Schedule
1 Park the machine on level ground within reach of a

compressed air line. Stop the engine and remove the
key. Open the engine compartment rear door.
2 After allowing the engine to cool down, remove any

debris from the radiator D that is accessible.
3 Use a brush to remove any other debris from the coolant

radiator D. Then blow through with compressed air.
4 Inspect the radiator for damage.
5 Close and latch the engine compartment rear door.
174341
9803/8500 Issue 2*
10 - 10 10 - 10
Engine (cont'd)
* Note: The upper illustration shows the Peugeot engine, the
lower illustration shows the JCB Diesel engine.
Checking the Alternator Belt Tension
1 Park the machine on level ground.
2 Stop the engine.
*4 Check the alternator belt tension which should be as

follows:
A
Peugeot engine - 10 mm (3/8 in) slack at point X.
X
JCB Diesel engine - 7 mm (0.28 in) slack at point X. C
5 If the belt requires adjusting proceed as below Adjusting
the Alternator Belt.
! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5
Adjusting the Alternator Belt
1 Loosen nut A and bolt B which secure the alternator.
2 Adjust the fan belt by:

B 174350
Peugeot engine - turning bolt C to give 10 mm (3/8 in)

slack at point X.
*
JCB Diesel engine - reposition the alternator to give 7 mm
(0.28 in) slack at point X.
3 Tighten nut A and bolt B. A

4 Close the engine compartment rear door.
Fitting a New Alternator Belt
1 Carry out step 1 of Adjusting the Alternator Belt.
2 Turn bolt C or reposition the alternator to slacken the belt

sufficiently to allow removal. Remove the belt.
3 Fit the new belt over the pulleys.
4 Carry out Steps 2 to 4 of Adjusting the Alternator Belt.

B
S255830
9803/8500 Issue 2*
11 - 1 11 - 1
Windscreen Washer
Fill the windscreen washer bottle A with a suitable liquid. The
liquid should contain a de-icing fluid to prevent it freezing. Do
not use engine coolant antifreeze.
174450
9803/8500 Issue 1
Section A Optional Attachments Section A
Contents Page No.
Quick Release Couplings 1-1
Connecting/Disconnecting Hoses 2-1
Shovels 3-1
General Purpose and Light Duty Shovels 3-1
6-in-1 Shovels 3-1
Pallet Forks 4-1
Manure/Silage Fork with Top Grab 5-1
Attachment Frame 6-1
* Backhoe Attachment
Technical Data 7-1
Routine Maintenance 7-1
Circuit Description 7-2
Valve Block Removal & Replacement 7-3
Valve Block Dismantling & Assembly 7-4
Pressure Testing 7-6
Carriage Clamp Mechanism 7-7
Stabilisers 7-8
Dipper & Boom Removal & Replacement 7-9
Ram Removal & Replacement 7 - 11
Ram Dismantling & Assembly 7 - 13
GENERAL INFORMATION
When fitting hydraulically operated optional attachments to the Robot the following
points should be noted:
When a Hammer or Earth Drill attachment is required a drain line must be fitted to
the machine. These two attachments can only be used on machines with High-
Flow circuit fitted.
Extra auxiliary relief valves can be fitted to the valve block and set to the required
pressure to provide protection for certain attachments where necessary. The
Standard Sweeper must have an auxiliary relief fitted but the Sweeper/Collector
already has a cross line relief fitted on the unit. The Manure/Silage Fork with Grab
does not require auxiliary relief valves.
Care must be taken if using attachments from other machines as the hydraulic
fluids may not be compatible.
9803/8500 Issue 3*
1-1 Quick Release Couplings 1-1
Flat face quick release couplings allow the operator to It is not possible to vent all residual pressure. Loosen the
remove and install attachments swiftly and efficiently. The connection one full turn and allow the pressure to
Skid Steer Attachment pipework has two male couplings dissipate. Keep face and hands well clear of pressurised
fitted. The attachment hoses have corresponding female hydraulic oil and wear protective glasses.
couplings fitted. HYD 4-3
! WARNING Before connecting or removing any hydraulic hose, residual

The external surfaces of the couplings must be clean hydraulic pressure trapped in the service hose line must be
* before connecting or disconnecting. Ingress of dirt will vented (see Connecting/Disconnecting Hydraulic Hoses
cause fluid leaks and difficulty in connecting or on page 2 - 1).
disconnecting. You could be killed or seriously injured by
faulty Quick Release Couplings. Connecting Quick Release Couplings
2-4-1-15
The quick release couplings should be trouble free and 1 Remove any residual hydraulic pressure trapped in the
relatively easy to connect and disconnect, provided they are service line hose.
kept clean and used correctly. The recommendations listed
below should always apply when using flat face quick release 2 Wipe the two faces of the male and female couplings
couplings. and make sure they are clean.
Finally, please read the correct fitting and releasing 3 Make sure that ball C in the female coupling is located in
procedures before installing or removing any optional one of its slots.
attachment fitted with quick release couplings.
4 Fit the male coupling into the female coupling. To ensure
Quick Release Couplings - Do's & Don'ts that the coupling is not accidentally released, rotate
sleeve E half a turn and make sure that the locking ball
DO wipe the two faces of the coupling and make sure they C does not align with slot D.
are clean before connecting.
DO make sure the outside sleeve (female coupling) is pulled

Disconnecting Quick Release Couplings
back when disconnecting.
1 Release any residual hydraulic pressure trapped in the
DO connect and disconnect a new coupling two or three service line hose.
times to 'work' the PTFE seals - sometimes a new coupling
will stick if the seals have not been 'worked'. 2 Align slot D with ball C.
DO use a spanner on the hexagon flats of the coupling when 3 Pull back sleeve E to release the coupling.
fitting adaptors.
DO use a rubber or hide hammer to disconnect a coupling if

it sticks - sticking may occur if there is dirt present in the 169490
coupling.
DON'T attempt to re-connect a damaged half coupling - this

will destroy the seals and necessitate replacing both half
couplings.
DON'T leave the coupling where it may be run over by a

machine or otherwise crushed - this will distort the coupling C
sleeve and prevent correct connection and disconnection.
E
DON'T clamp on the smooth diameter of the coupling when
D
fitting adaptors - always use the hexagon.
DON'T try to turn the sleeve (female coupling) when the

coupling has been disconnected - the locking ball will wedge
underneath the sleeve and destroy the coupling.
DON'T damage the faces of the couplings - this can prevent

connection and disconnection, or damage seals and cause
leakage.
DON'T try to dismantle the couplings - they are non

serviceable parts. If a coupling is damaged it should be
replaced with a new one.
! WARNING
9803/8500 Issue 3*
2-1 Connecting/Disconnecting Hydraulic Hoses 2-1
Some attachments are hydraulically powered. The following

paragraphs describe how to connect and disconnect the 1 Carry out steps 1 and 2 of connecting the hoses.
hydraulic hoses safely.
2 Disconnect the hoses. See Connecting/Disconnecting
! WARNING Quick Release Couplings on page 1 - 1.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before ! WARNING
disconnecting or connecting hydraulic hoses, stop the Fine jets of hydraulic fluid at high pressure can penetrate
engine and operate the controls to release pressure the skin. Do not use your fingers to check for hydraulic
trapped in the hoses. Make sure the engine cannot be fluid leaks. Do not put your face close to suspected
started while the hoses are open. leaks. Hold a piece of cardboard close to suspected
INT-3-1-11/1 leaks and then inspect the cardboard for signs of
Connecting the Hoses INT-3-1-10/1
1 Stop the engine. When the engine has stopped turn the 3 Check for leaks. See step 4 of Connecting the Hoses.
starter key to IGN.
2 Relieve system pressure as follows: operate the Auxiliary

Attachment Control Switch or the Auxiliary Attachment
Detent Switch for a short time to relieve residual
pressure in the hydraulic circuit.
Turn the starter key to OFF and remove the key.
This will release any hydraulic pressure trapped in the

hoses.
3 Connect the hoses. See Connecting Quick Release

Couplings on page 1 - 1.
! WARNING
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
INT-3-1-10/1
4 Check for leaks as follows:
a Start the engine.

b Operate the Auxiliary Control Switch. This will build
up pressure in the hoses.
c Switch off the engine. Remove the starter key. Check
for signs of leakage at the hose connections.
Disconnecting the Hoses
9803/8500 Issue 1
Thank you very much
for your reading.
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Then Get More
Information.

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JCB 150 ROBOT Service Repair Manual SN678000 Onwards PDF

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General Information 1

Care & Safety 2

Publication No. 9803/8500 Engine K

1 = General Information - includes torque settings and service tools.

Contents Page No.

Torque Settings 2-1

Sealing and Retaining Compounds 5-1

The serial number of the chassis, engine, lift arm and

Machine Identification Plate

6 Manufacturer Location (E = England)

The chassis serial number is stamped on the front edge of

The hydraulic pump unit serial number is stamped on a plate

UNF Grade 'S' Bolts

Bolt Size Hexagon (A/F) Torque Settings

1/4 (6.3) 7/16 14 1.4 10

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque Settings

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00281 AVO Meter

3 892/00286 Surface Temperature Probe

4 892/00284 Microtach Digital Tachometer

5 892/00282 Shunt - open type

6 892/00285 Hydraulic Oil Temperature Probe

* 993/85700 Battery Tester

Hydraulic Circuit Pressure Test Kit

892/00253 Pressure Test Kit

892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in2)

* 892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in2)

892/00254 Replacement Hose

Flow Test Equipment

892/00268 Flow Monitoring Unit

892/00223 Hand Pump Bonded Washers

1606/0003 3/8 in x 1/4 in

Male Cone Blanking Plug

'T' Adapters Female Connectors

* 993/68100 Slide Hammer

JCB Activator A cleaning primer which speeds the curing rate of

JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic

Loctite 243 4101/1101 Use 4101/0251

Loctite 932 4101/0402 JCB Threadlocker 4101/0451

Loctite Activator N 4104/0101 Aerosol JCB Activator 4104/0251

JCB Cleaner & Degreaser 4104/1538 Aerosol JCB Cleaner/Degreaser 4104/1557

Contents Page No.

General Safety 2-1

Operating Safety 3-1

Maintenance Safety 4-1

Safety Decals 5-1

All construction and agricultural equipment can be

If you are unsure of anything, about the machine or the job,

Maintenance Safety (cont'd)

Keep all decals clean and readable. Replace lost or

Safety Decals (cont'd)

Contents Page No.

Fuel System 2-1

Service Schedules 3-1

Loader Arm Safety Strut 4-1

* Body and Framework

Contents Page No.

Fluids, Capacities and Lubricants - except North America

ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION

Hydraulic System 65 litres JCB 15W/40 Multigrade API CE 15W 40